How is additive manufacturing being applied to aerospace metals?

Metal additive manufacturing (AM) enables complex geometries not possible with conventional methods. Processes: Powder Bed Fusion - Laser (SLM, DMLS) or electron beam (EBM) melts metal powder layer by layer; Directed Energy Deposition - Wire or powder fed into melt pool, larger parts, faster; and Binder Jetting - Binder bonds powder, sintered to full density. Aerospace applications: Fuel nozzles (GE LEAP), Structural brackets, Tooling and fixtures, and Replacement parts for legacy aircraft. Materials: Ti-6Al-4V - Most common, well-characterized; Inconel 718, 625 - Nickel superalloys for high temp; AlSi10Mg - Aluminum for lighter parts; and Stainless steels. Challenges: Porosity, surface finish, Residual stresses, build orientation effects, Qualification and certification (limited standards), and Inspection methods development. Benefits: Part consolidation (fewer fasteners, joints), Weight reduction through optimized geometry, Reduced lead time for complex parts. AM specifications developing (AMS7003, AMS7004).